Adjusting shaft bevel gear: Audi A3

🧭 Before you start

Fits: Audi A3 (8L, 1996–2003)

• Special tools named: dial gauge

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• Only increase tightening torque slowly. Stop and and check friction torque several times.If the specified friction torque is exceeded, the soldering wire must be renewed and the adjustment procedure repeated.
• Finally, check again whether dial gauge returns to "“0”" with master gauge VW 385/30 set to 3 mm preload, otherwise repeat measurement.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Press large tapered roller bearing outer race for shaft bevel gear into pinion housing with thrust piece2050.
2. Press small tapered roller bearing outer race for shaft bevel gear into pinion housing with press toolVW 473.
3. Press large tapered roller bearing inner race onto shaft bevel gear using tubeVW 415 A.
4. Insert a piece of soldering wire ∅ 1.5 mm (item A) instead of shim "“S4”".
5. Fit spacer ring (B) with chamfer facing tapered roller bearing inner race.

6. Install shaft bevel gear.
7. Fit small taper roller bearing inner race and output flange and attach hexagon nut.
8. Screw in a hexagon bolt M10 (item A) to lock flange.
9. Tighten hexagon nut to 20 Nm and unscrew hexagon bolt (A) a few turns or remove completely. — 20 Nm (15 lb-ft)
10. Measure friction torque.
11. If necessary, increase tightening torque until the specified friction torque is attained. [Note: Only increase tightening torque slowly. Stop and and check friction torque several times.If the specified friction torque is exceeded, the soldering wire must be renewed and the adjustment procedure repeated.]
12. Adjust the following friction torques:
13. Remove shaft bevel gear and carefully remove crushed soldering wire.
14. Measure thickness of soldering wire at a point where it is well crushed and where there is no lip.
15. Select required shim thickness(es) "“S4”" from following table:
16. Fit shim(s) "“S4”" and install shaft bevel gear.
17. Tighten hexagon nut for output flange.
18. Measure friction torque .
19. Correct adjustment if necessary by fitting a thinner shim "“S4”" (to give more friction torque) or a thicker shim "“S4”" (to give less friction torque).
20. Install pinion housing with shaft bevel gear and fitted shim "“S4”".
21. Do not install O-ring.
22. Adjust setting ring of universal measuring toolVW 385/1 to dimension (a) = 75 mm.
23. Set adjustable ring to dimension (b) = 32 mm.
24. Assemble universal measuring tool as shown in illustration; use dial gauge extensionVW 385/20 (length 3 mm).
25. Set universal master gaugeVW 385/30 to "“Ro”" = 36.20.
26. Set dial gauge to "“0”" with a preload of 3 mm.
27. Place end measuring plate on face of shaft bevel gear.
28. Insert universal measuring tool.
29. Attach cover and tighten hexagon bolts.
30. Using the adjustable ring, move the centring disc outwards as far as possible so that the measuring tool can still just be turned by hand.
31. Turn measuring tool until tip of dial gauge contacts end measuring plate and gauge indicates maximum deflection (return point). The measured value is dimension "“e”" (in red scale) (in example: 0.47 mm).
32. Remove universal measuring tool. [Note: Finally, check again whether dial gauge returns to "“0”" with master gauge VW 385/30 set to 3 mm preload, otherwise repeat measurement.]
33. Select required shim thickness(es) "“S3”" from following table:
34. Remove pinion housing with shaft bevel gear.
35. Install determined shim(s) "“S3”".
36. Insert universal measuring tool and measure dimension "“R”".

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